Rapid curing aldehyde resin-polyisocyanate composition and method for producing hybrid polymer

Abstract

A hybrid polymer composition and a method for forming it is provided, comprising a first part A comprising a polyurethane catalyst and an aldehyde resin pre-polymer and a second part B comprising a polyisocyanate pre-polymer and an aldehyde resin cure accelerator. Methods are also provided for forming a composite with a two part hybrid polymer composition and a fibrous web material.

What is claimed is: 
     
       1. A method for forming a hybrid polymer composition, comprising the steps of:
 preparing a first part that includes a phenol-aldehyde pre-polymer and a polyurethane catalyst; 
 preparing a second part that includes a polyisocyanate pre-polymer and a phenol-aldehyde cure accelerator; 
 combining the first part and the second part to form a hybrid pre-polymer composition; and 
 thereafter applying the hybrid pre-polymer composition to a substrate material that includes cellulose, lignocellulose, and combinations thereof, inducing reaction of the hybrid pre-polymer composition to form the hybrid polymer composition, including curing the applied hybrid pre-polymer composition to form the hybrid polymer composition, wherein said hybrid pre-polymer composition has a gel time, as measured from the mixture of the pre-polymer composition, of less than about 9000 seconds at ambient temperature. 
 
     
     
       2. The method of  claim 1 , whereby the step of combining the first part and the second part to form a hybrid pre-polymer composition is performed by microencapsulating the first part in the second part, or alternatively, by microencapsulating the second part in the first part to form said hybrid pre-polymer composition. 
     
     
       3. The method of  claim 1 , whereby the reaction of said hybrid pre-polymer composition is induced by mixing, by pressure, by applying heat, or combinations thereof. 
     
     
       4. The method of  claim 1 , wherein the polyurethane catalyst is selected from a group consisting of: Lewis bases, Lewis acids, insertion catalysts, metal catalysts, alkali metal salts of organic acids and phenols, and mixtures thereof 
     
     
       5. The method of  claim 1 , wherein the polyisocyanate pre-polymer is at least a monomer of diphenylmethane diisocyanate and has at least two isocyanate functional groups. 
     
     
       6. The method of  claim 1 , wherein the phenol-aldehyde resin cure accelerator is selected from a group consisting of: lactones, organic carbonates, carboxylic acid esters; ammonia reaction products of lactones, organic carbonates, carboxylic acid esters; and mixtures thereof. 
     
     
       7. The method of  claim 1 , wherein the gel time is less than about 3300 seconds at ambient temperature. 
     
     
       8. The method of  claim 1 , wherein the gel time is less than about 2000 seconds at ambient temperature. 
     
     
       9. The method of  claim 1 , wherein the gel time is less than about 600 seconds at ambient temperature. 
     
     
       10. The method of  claim 1 , wherein the gel time is less than about 180 seconds at ambient temperature. 
     
     
       11. The method of  claim 1 , wherein the gel time is less than about 60 seconds at ambient temperature. 
     
     
       12. The method of  claim 1  wherein said phenol-aldehyde pre-polymer is selected from the group consisting of: aqueous and powdered resoles wherein said aqueous resoles may have a portion of their water substituted by aliphatic alcohols, diols, triols, or mixtures thereof. 
     
     
       13. The method of  claim 1  wherein said hybrid polymer composition is used for the manufacture of: lignocellulosic composites selected from a group consisting of: plywood, laminated veneer lumber, oriented strandboard, oriented strand lumber, parallel strand lumber, scrim strand lumber, particle board, medium density fiberboard, high density fiberboard, and hardboard, wherein said lignocellulosic composites further including veneers, overlays, low pressure laminates, and high pressure laminates; finger jointed lumber, I joists, glue laminated lumber, overlays, and high pressure laminate;
 a fibrous web composite further comprising a fibrous web material and said hybrid polymer composition, wherein the fibrous web material is selected from a group consisting of: cellulose, glass fiber, carbon fiber, synthetic organic fiber, and combinations thereof.